Fiber reinforced cellular pvc

ABSTRACT

The present invention relates to exterior siding, trim and rigid architectural assemblies for buildings.

This application claims priority to Provisional U.S. Patent ApplicationSer. No. 61/585,919, filed Jan. 12, 2012.

FIELD OF THE INVENTION

The present invention relates to exterior siding, trim and rigidarchitectural assemblies for buildings.

BACKGROUND

Traditional exterior systems for wood-frame construction homes involveplywood or oriented strandboard (OSB) sheets nailed to wood framing,covered with a vapor barrier, and covered in a siding material such as,for example, wood shingles, wooden clapboard siding, vinyl siding, orfiber-cement composite siding.

Cellular polyvinylchloride (“PVC”) materials have been used in thehousing industry for trim materials for some time. Cellular PVC is easyto cut, more durable than wood, and does not succumb to rotting.However, cellular PVC is not as rigid as wood, and is more susceptibleto temperature-induced expansion and contraction, which limits itsapplicability for exterior applications such as siding and trim.

Various attempts have been made to improve the suitability of cellularPVC for exterior systems.

For example, U.S. Pat. No. 4,482,589A discloses a self carrying platformof the sandwich type forming a closed goods accommodating space,preferably for refrigerator/freezer trailers, comprising a core (15) andsurface layers (16) laminated thereto. The surface layers consist ofmetal plates and the core of a constructional cellular plastics onPVC-basis.

In another example, U.S. Pat. No. 5,264,174 discloses a process forstably producing a compositely reinforced polypropylene compositionhaving less warpage deformation and good moldability which includes thesteps of using an extruder having at least three feed inlets, feeding anorganic peroxide and a polypropylene resin selected from (a) apolypropylene modified by grafting an unsaturated organic acidthereonto, (b) a mixture of the resulting modified polypropylene and anunmodified polypropylene, (c) a mixture of an unsaturated organic acidand an unmodified polypropylene or (d) mixtures of the foregoing to theextruder through the first feed inlet of the extruder, feeding thelamellar inorganic filler thereto through the second feed inlet disposedat a position where the resin mixture is sufficiently melted andkneaded, feeding the glass fiber through the third feed inlet, and thenmelting and kneading these materials.

In another example, U.S. Pat. No. 5,538,784 states “Inorganicfiber-reinforced thermoplastic articles are produced from preciselyproportioned feed mixtures of particles of thermoplastic polymer, apolymer modifier and inorganic fiber bundles supplied, under specifiedconditions, directly to an injection molding apparatus. The articlesexhibit exceptionally superior heat deflection temperature compared toarticles produced from feeds which are precompounded prior to injectionmolding.”

In another example, U.S. Pat. No. 5,830,395 discloses a process formaking a substantially uniform composition of short aramid fibers andpolymer wherein the fibers are provided with a significant moisturecontent to improve handling characteristics and are partially dried andopened by shear forces in an extruder before contact with the polymer inthe extruder.

In another example, U.S. Pat. No. 5,979,135 A discloses a siding panelcomprising: a vinyl sheet having an upper edge; and a fabric tapeaffixed to the upper edge of the vinyl sheet,

wherein the fabric further comprises: a plurality of longitudinal warpyarns; and at least one weft yarn woven through the warp yarns to form arelatively solid band having two edge and a plurality of loops extendingfrom one edge of the band.

In another example, U.S. Pat. No. 6,003,277 discloses an integrallyreinforced lineal building component, comprising in combination: anelongated member having a substantially constant cross-sectional shapeextending along substantially the entire length of said buildingcomponent and comprised of cellular material forming the body and majorcross-sectional portion of said building component; and an elongatedreinforcement element having a substantially constant cross-sectionalshape extending along substantially the entire length of said buildingcomponent and disposed inside said elongated member and bondedintegrally thereto, said reinforcement element having at least twoflange-like portions integrally attached and disposed at an angle withrespect to one another extending lengthwise of and generally parallel tosaid elongated member.

In another example, U.S. Pat. No. 6,122,877 discloses a siding assemblyfor an exterior wall surface of a building made up of a plurality ofsiding units, said units adapted to be affixed to a building withsimilar units in overlapping horizontal courses with the units of eachcourse lying in overlapping relation, said building having a supportstructure, each of said units comprising: a profile made of a compositematerial including a thermoplastic polymer and a cellulosic fiber, saidmaterial comprising about 35-60 parts of fiber and about 45-70 parts ofpolymer per each 100 parts of said composite material; said unitcomprising a main body portion including a front face and a rear face,said front face being exposed on assembly of said siding unit on abuilding, said front face being convex; an upper portion extending fromsaid main body portion, said upper portion having a plurality of slots,said upper portion including a tongue means; and a groove means sizedand configured to mate with said tongue means, wherein said groove meansis located behind said main body portion.

In another example, U.S. Pat. No. 6,344,268 B1 discloses foamedpolymer-fiber composites, building materials and methods of making suchbuilding materials . . . . The composites include about 35-75 wt. % of apolymeric resin, about 25-65 wt. % fiber and have a specific gravity ofless than about 1.25 g/cc. The low density is provided by theintroduction of a blowing agent or gas into a molten precursor of thecomposite during thermo forming, such as in an extrusion operation.

In another example, U.S. Pat. No. 6,408,580 B1 discloses a siding stripcapable of engaging an adjacent siding strip to cover a portion of astable mounting structure, comprising: an elongated body including amain portion, a fastener portion, a fastener receiving section, and atleast one first integral portion having an outer surface that contrastsin color with an outer surface of the main portion for simulating theappearance of grout or chinking, whereby said contrasting first integralportion is exposed when the adjacent siding strip is engaged with saidelongated body to simulate the appearance of grout or chinking betweenthe adjacent strip and the elongated body.

In another example, U.S. Pat. No. 6,682,814 B1 discloses a sidingassembly and method of manufacture are disclosed. U.S. Pat. No.6,682,814 B1 states “Each siding unit is a profile of a compositematerial which includes a thermoplastic polymer and a cellulosic fiber.The preferred siding unit has a tapered thickness and a convex face.Each siding unit is interconnected to adjacent siding units with atongue and groove mechanism. The preferred siding profile has aplurality of webs, and the exposed portion of the siding has a capstocklayer to improve weatherability. The exposed width of the siding's facemay be adjustable. The siding units are interconnected end-to-end byinserts which are positioned by means of an adhesive or thermalwelding.”

In another example, U.S. Pat. No. 7,331,270 B2 discloses a non-metallicarmor article comprising a pultruded housing having disposed therein atleast one dry ballistic impact resistant broad goods sheet secured bythe pultruded housing, the housing formed from a cured, fiberimpregnated resin, opposing faces of said broad goods sheet being spacedfrom said housing and edge portions of said broad good sheet being incontact with said housing and fixed in position with respect thereto,said housing extending around a cross-section of said broad goods sheetremote from said edge portions and being integrally formed.

In another example, U.S. Pat. No. 7,482,038 discloses an in-line processfor forming prefinished siding manufactured from cellularpolyvinylchloride comprising embossing, milling, parting, punching andcoating the polyvinylchloride such that the resulting siding is suitedfor use in an environment exposed to a wide range of fluctuatingtemperatures and moisture.

In another example, U.S. Pat. No. 7,638,187 B2 discloses a compositecomprising: a fiber having a lumen with voids; a suspension drawn intothe lumen to beneficiate the fiber, the suspension including a chemicalblowing agent; and a polymeric material imbedded with the fiber; wherebythe natural voids of the lumen are preserved by the suspension causingthe fiber to maintain natural density and strength characteristics.

In another example, U.S. Pat. No. 7,749,424 B2 discloses a method ofmaking a fenestration framing member that includes the steps of: (a)providing a core having a cross section and a lengthwise geometrydesired for said fenestration framing member, (b) placing a fiberglassmat around said core to form a fiberglass-enclosed core, and (c) vacuuminfusing resin into said mat to form a fenestration framing member ofdesired cross section and lengthwise geometry that includesfiberglass-reinforced resin enclosing said core, wherein said step (c)includes: (c1) placing a peel ply around said fiberglass-enclosed core,(c2) placing a flow medium over said peel ply, (c3) placing tubing oversaid flow medium, said tubing having apertures, said tubing comprises aspiral wrap of plastic ribbon having said apertures as spiral aperturesformed by gaps between wraps of said ribbon, (c4) placing the product ofsaid step (c3) into a vacuum enclosure, (c5) connecting said tubing to avacuum source and a source of resin to draw resin into said vacuumenclosure and infusing the resin through the apertures in said tubing,through said flow medium and said peel ply into said fiberglass mat,(c6) removing said vacuum enclosure, and (c7) removing said tubing, saidflow medium and said peel ply leaving said fenestration framing member.

In another example, U.S. Pat. No. 7,776,399 discloses a method forforming a polyurethane coated cellular polyvinylchloride board.

In another example, U.S. Pat. No. 8,053,528 B2 discloses an aqueousbinder composition for use in making fiber mats, the binder compositioncomprising: a urea-formaldehyde resin; and an aqueous emulsion of acopolymer prepared by polmerization of a mixture comprising about 20 wt% to about 60 wt % styrene, about 20 wt % to about 50 wt % of an alkyl(meth)acrylate, about 5 wt % to about 30 wt % acrylonitrile, and about 1wt % to about 15 wt % of an unsubstituted or substituted acrylamide,where all weight percents are based on a total weight of the mixture.

In another example, U.S. Patent Application US20030021915A1 disclosescellulose-polymer composites characterized by the cellulose componentbeing thoroughly encapsulated by the polymer component, varying densitywhich allows high strength over a wide range of temperatures andgenerally low weight are provided. Composites may be extruded orcoextruded into a variety of products including wood-like deckingmaterials with natural wood coloring and texture. Processes related tothe manufacture of the composites are also provided.

In another example, U.S. Patent Application US20040009338A1 disclosespolymeric building materials . . . which include a compositereinforcement comprising continuous filaments of fibers substantiallyoriented in at least a first direction within a polymeric matrix. Thecomposite reinforcement includes a higher tensile strength and a lowerrigidity than aluminum. The building material further includes acapstock polymeric material disposed substantially over the compositereinforcement. The building material is resistant to heat deformationand corrosion. This invention also includes methods for constructingsuch polymeric composite building materials, including in the preferredembodiments, pultrusion and extrusion steps.

In another example, U.S. Patent Application US20040048055A1 discloses asynthetic wood structural member, comprising: a synthetic wood bodycomprising a synthetic polymer, the synthetic wood body having alongitudinal axis; at least one continuous fiber composite reinforcingrod element positioned within the synthetic wood body to increase thestiffness of the synthetic wood structural member, the at least onecontinuous fiber composite reinforcing rod element having a longitudinalaxis, the longitudinal axis of the at least one continuous fibercomposite reinforcing element being essentially parallel to thelongitudinal axis of the synthetic wood structural member.”

In another example, U.S. Patent Application US20060103045A1 discloses amethod for incorporating wet use chopped strand glass (WUCS) in a screwextrusion process is provided. A polymeric resin is added to an extruderin a polymer feed zone and conveyed to a first compression zone wherethe resin is at least partially melted. The molten resin is conveyed toa high volume zone where WUCS fibers are added. In the high volume zone,the flights of the screw may have a greater pitch to facilitate theintroduction of the WUCS into the extruder. The molten resin/fibermixture is conveyed to a second compression zone where the resin andfibers are intimately compounded. Next, the molten resin/fiber mass isconveyed to a low pressure zone where moisture evaporated from thefibers is released through an opening. The resin/fiber mixture is thenconveyed through a compression/die feed zone to further compound and mixthe resin and fibers.

In another example, U.S. Patent Application US20060234028A1 discloses aprocess for manufacturing composite sheets, in which: a web of yarns, inthe form of a mat of continuous yarns, a woven, a knit or an assembly ofcontinuous non-interlaced yarns, is continuously deposited on a movingsubstrate, this web comprising at least one organic material and atleast one reinforcing material; a powder of an organic material capableof forming a coating layer under the action of heat is deposited on atleast one side of said web; the web coated with the powder is heated toa temperature sufficient to melt the powder; the web is compressed andcooled so as to form a composite strip; and the strip is cut in the formof sheets or wound up on a rotating support.

In another example, U.S. Patent Application US20070009688A1 discloses areinforcement backing for cladding comprising: about 30 to about 98% byweight of at least one thermoplastic bonding material; and about 2 toabout 70% by weight dried wet reinforcement fibers having a meltingpoint that is above the melting point of said thermoplastic bondingmaterial.

In another example, U.S. Patent Application US20070078191A1 discloses acomposition for forming a reinforced composite siding product and acomposite siding product formed by an extrusion process utilizing thecomposition is provided. The mixed resin formulation utilized to formthe composite siding product includes a polymeric resin, a filler, aprocessing aid, at least one lubricant, and a thermal stabilizer. In apreferred embodiment, the polymer resin is polyvinyl chloride and thefiller is talc. The mixed resin formulation may be extruded with areinforcement material in a screw extrusion process to form a compositesiding product. One or more reinforcing fibers may be utilized in theextrusion process. The reinforcement fibers may be present in the finalproduct in an amount up to 25% by weight of the final product. In atleast one preferred embodiment, the reinforcement fibers are glassfibers. A weatherable cap may be co-extruded to form the finalreinforced, foamed composite siding product.

In another example, U.S. Patent Application US20080182074A1 discloses amelt bonded multilayer composite comprising: (a) at least one layer of athermoplastic elastomer composition comprising (i) from about 50 toabout 100 percent by weight of a thermoplastic elastomer based on thetotal weight of the composition, and (ii) from about 0 to about 50percent by weight of an adhesion promoter based on the total weight ofthe composition; and (b) at least one layer of a rigid polyvinylchloride polymer composition.

In another example, U.S. Patent Application US20100058691A1 disclosescellular PVC siding, trim and architectural assemblies.

In another example, U.S. Patent Application US20100075104A1 discloses aprocess for manufacturing composite sheets based on PVC and a network oflong fibers, said process comprising the following steps: dispersing PVCin powder form in said network; subjecting the dispersion to analternating electric field with a sufficient intensity and for asufficient time in order to distribute the powder in the network; andheating the dispersion under pressure until the powder forms acontinuous matrix.

In another example, U.S. Patent Application US20100255248A1 discloses aprocess for the manufacture of a weather resistant laminate comprisingthe steps of providing a resin impregnated fibrous layer, curing theresin of the resin impregnated fibrous layer in a first curing step,wherein in said first curing step a contact pressure is applied to theresin impregnated fibrous layer, applying a resin coating layer on theat least partially cured resin impregnated fibrous layer, curing theresin of the resin coating layer in a separate second curing step andlaminating the resin impregnated fibrous layer on at least one surfaceof a carrier layer before, during or after the first curing step, orlaminating the cured and coated resin impregnated fibrous layer on atleast one surface of the carrier layer before, during or after thesecond curing step.

In another example, PCT Application WO2008027363A2 discloses a method ofmaking a fenestration framing member that includes the steps of: (a)providing a core (30 or 60) having a size and shape desired for saidfenestration framing member, (b) placing a fiberglass mat (32 or 64) onsaid core to form a fiberglass-engaged core, and (c) vacuum infusingresin into said mat of said fiberglass-engaged core to form afenestration framing member (28 or 68) of desired size and shape thatincludes fiberglass-reinforced resin engaging said core.

In another example, PCT Application WO99/24651 discloses a process formanufacture of reinforced composites . . . that allows for the directmixing of discontinuous reinforcement such as wet chopped strands ofglass fibers or continuous reinforcement such as class strands, with anaqueous suspension of a solution of polymerized polymer, such aspolyvinyl chloride.

In another example, the Enduro Tuff Span Catalog Data Guide discloses amulti-layer composite material comprising three layers of continuous,straight bi-directional reinforcements sandwiched between 2 layers ofembossed resin rich surface mats.

In another example, the ICC-ES/ESR-2806 Evaluation Report discloses afiber reinforced plastic (FRP) lap siding used as exterior wallcovering. The product is a pultruded polyester and glass fiber compositematerial.

In another example, the document located at the web sitehttp://www.resolite.com/products/roofingandsiding/1-1-2design.htmldiscloses a chopped strand fiberglass reinforced composite panel.

Previous attempts to improve the suitability of cellular PVC forexterior systems, in particular the resistance to temperature-inducedexpansion and contraction were unsuitable, in that the particularreinforcement utilized did not convey the desired resistance totemperature-induced expansion and contraction, or the bonding of thereinforcement to the cellular PVC was deficient.

The present invention solves these problems by providing a cellular PVCmaterial that is reinforced with fibers, comprising continuous strandsthat are bonded to the cellular PVC. The reinforcing fibers provideresistance to temperature-induced expansion and contraction of thecellular PVC material along the direction of the fibers.

SUMMARY

In one embodiment, the present invention provides a compositioncomprising cellular PVC reinforced with at least one continuous fiberoriented in a first direction within the cellular PVC material, whereinthe at least one continuous fiber is bonded to the cellular PVC, andwherein the at least one continuous fiber provides resistance totemperature-induced expansion and contraction along the direction of theat least one continuous fiber.

In one embodiment, the at least one continuous fiber is coated with anagent that bonds the at least one continuous fiber to the cellular PVC.

In one embodiment, the at least one continuous fiber is selected fromthe group consisting of co-mingled silicate based fiber andthermoplastic fiber, non-comingled silicate based fibers, non-comingledcarbon based fibers and non-comingled polyamide based fibers.

In one embodiment, the at least one continuous fiber is a non-comingledsilicate based fiber.

In one embodiment, the non-comingled silicate based fiber is anon-comingled glass fiber.

In one embodiment, the at least one continuous fiber is a co-mingledsilicate based fiber and thermoplastic fiber.

In one embodiment, the co-mingled silicate based fiber is a glass fiberand a thermoplastic fiber.

In one embodiment, the first direction is along the direction ofextrusion of the cellular PVC material.

In one embodiment, the present invention provides a method to produce acomposition comprising cellular PVC reinforced with at least onecontinuous fiber oriented in a first direction within the cellular PVCmaterial, wherein the at least one continuous fiber is bonded to thecellular PVC, and wherein the at least one continuous fiber providesresistance to temperature-induced expansion and contraction along thedirection of the at least one fiber comprising the steps of:

-   -   a) providing a starting mixture comprising PVC powder or pellets        and a blowing agent;    -   b) heating the starting mixture;    -   c) extruding the starting mixture through a form;    -   d) combining the extrudate with at least one continuous fiber;    -   e) passing the extrudate combined with the at least one        continuous fiber in to a calibration chamber, allowing the        combined extrudate to form cellular PVC reinforced with at least        one continuous fiber oriented in a first direction within the        cellular PVC material, and allowing the cellular PVC reinforced        with at least one continuous fiber oriented in a first direction        within the cellular PVC material to reach its final desired        dimensions as defined by the calibration chamber dimensions; and    -   f) cooling the cellular PVC reinforced with at least one        continuous fiber oriented in a first direction within the        cellular PVC material, and cutting the cellular PVC to the        desired length.

In one embodiment, the at least one continuous fiber is coated with anagent that bonds the fibers to the cellular PVC.

In one embodiment, the first direction is along the direction ofextrusion of the cellular PVC material.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated herein and form partof the specification, illustrate various embodiments of the presentinvention and, together with the description, further serve to explainthe principles of the invention and to enable a person of ordinary skillin the art to make and use the invention. In the drawings, likereference numbers indicate identical or functionally similar elements. Amore complete appreciation of the invention and many of the attendantadvantages thereof will be readily obtained as the same becomes betterunderstood by reference to the following detailed description whenconsidered in connection with the accompanying drawings, wherein:

FIG. 1 shows one embodiment of the cellular PVC reinforced with at leastone continuous fiber oriented in a first direction coated with an agentthat bonds the fibers to the cellular PVC of the present invention,wherein the fibers are provided as separate strands and are alignedalong the direction of extrusion and are distributed in a single layerwithin the cellular PVC.

FIG. 2 shows an alternate embodiment of the cellular PVC reinforced withat least one continuous fiber oriented in a first direction coated withan agent that bonds the fibers to the cellular PVC of the presentinvention, wherein the fibers are provided in the form of a tape and arealigned along the direction of extrusion and are distributed in a singlelayer within the cellular PVC.

FIG. 3 shows one embodiment of the apparatus used to manufacture thecellular PVC reinforced with at least one continuous fiber oriented in afirst direction coated with an agent that bonds the fibers to thecellular PVC of the present invention, wherein the fiber reinforcedcellular PVC material is extruded at right angles to the direction inwhich the starting PVC material is added. This method is known as the“crosshead method”.

FIG. 4 shows an alternate embodiment of the apparatus used tomanufacture the cellular PVC reinforced with at least one continuousfiber oriented in a first direction of the present invention coated withan agent that bonds the fibers to the cellular PVC, wherein the fiberreinforced cellular PVC material is in line to the direction in whichthe starting PVC material is added. This method is known as the “noncrosshead method”.

DETAILED DESCRIPTION

For clarity of disclosure, and not by way of limitation, the detaileddescription of the invention is divided into the following subsectionsthat describe or illustrate certain features, embodiments orapplications of the present invention.

Cellular PVC Suitable for Use in the Present Invention

While the present invention could utilize any polymeric matrix, thepresent invention is illustrated using a polymeric matrix comprisingcellular PVC.

Cellular PVC may be formed by any method in the art. It is understoodthat the choice of the method may be influenced by factors such as theend use of the item the particular cellular PVC material will be usedfor. For example, the cellular PVC suitable for use in the presentinvention may be made according to the methods disclosed in U.S. Pat.No. 5,783,613A. Alternatively, the cellular PVC suitable for use in thepresent invention may be made according to the methods disclosed in U.S.Pat. No. 5,786,399A. Alternatively, the cellular PVC suitable for use inthe present invention may be made according to the methods disclosed inU.S. Pat. No. 7,879,922 B2. Alternatively, the cellular PVC suitable foruse in the present invention may be made according to the methodsdisclosed in PCT Application WO2007141647A1. Alternatively, the cellularPVC suitable for use in the present invention may be made according tothe methods disclosed in United States Patent ApplicationUS20030027881A1. Alternatively, the cellular PVC suitable for use in thepresent invention may be made according to the methods disclosed inUnited States Patent Application US201000281801A1.

In one embodiment, the present invention employs a starting materialconsisting of PVC powder or pellets and a blowing agent. In oneembodiment the blowing agent comprises from about 0.4 to about 20% ofthe starting material. In an alternate embodiment, the blowing agentcomprises from about 4 to about 5% of the starting material. Thestarting material is then extruded through a die (such as, for example,the dies shown in either FIG. 3 or FIG. 4). The at least one continuousfiber is then added to the extrudate. The at least one continuous fibermay be added to the extrudate using a crosshead method. Alternatively,the at least one continuous fiber may be added to the extrudate using anon crosshead method.

In one embodiment, the extrusion process orients the at least onecontinuous fiber in a first direction. In one embodiment, the firstdirection is the direction in which the cellular PVC is extruded.

The extrudate containing the at least one continuous fiber oriented in afirst direction is then passed into a calibration chamber that allowsthe extrudate to expand to the final desired dimensions and bonds the atleast one continuous fiber oriented in a first direction to the cellularPVC material.

One of ordinary skill in the art would appreciate that the speed atwhich the cellular PVC material is extruded, the temperature at whichthe material is extruded, the shape and dimensions of the form throughwhich the starting material is extruded, the shape and dimensions of thecalibration chamber, and the temperature and pressure at which the dieand calibration chamber is maintained can influence the final propertiesof the cellular PVC material of the present invention. For example, one,or more than one of the parameters can be altered to influence thestrength of the bonding of the at least one continuous fiber to thecellular PVC. Alternatively, one, or more than one parameter may bealtered to influence the density of the cellular PVC material, and thelike.

In one embodiment, the at least one continuous fiber is coated with anagent that bonds the at least one fiber to the cellular PVC. In oneembodiment, the agent that bonds the at least one continuous fiber tothe cellular PVC of the present invention is coated on the at least onecontinuous fiber prior to addition to the cellular PVC material.Depending on the agent used, the agent may require activation prior toaddition to the cellular PVC in order for it to bond. Again, dependingon the agent used, the activation may be via pressure, heat, chemicalmeans, and the like. In one embodiment, the present invention utilizes aheat activated bonding agent.

In one embodiment, utilizing a heat activated bonding agent, the atleast one continuous fiber oriented in a first direction coated with anagent that bonds the fibers to the cellular PVC of the present inventionis pre heated prior to addition to the extrudate. In one embodiment, theat least one continuous fiber oriented in a first direction coated withan agent that bonds the fibers to the cellular PVC of the presentinvention is pre heated to a temperature from about 330° F. to about480° F. In an alternate embodiment, the at least one continuous fiberoriented in a first direction coated with an agent that bonds the fibersto the cellular PVC of the present invention is pre heated to atemperature from about 380° F. to about 400° F.

In one embodiment, the extrudate to which the at least one continuousfiber oriented in a first direction coated with an agent that bonds thefibers to the cellular PVC of the present invention is at a temperaturefrom about 320° F. to about 380° F. In an alternate embodiment, theextrudate to which the at least one continuous fiber oriented in a firstdirection coated with an agent that bonds the fibers to the cellular PVCof the present invention is at a temperature from about 340° F. to about370° F.

In one embodiment, the die is maintained at a pressure of about 1500 psito about 7000 psi. In an alternate embodiment, the die is maintained ata pressure of about 1500 psi to about 2000 psi.

In one embodiment, the extrudate passes into a calibration chamber,which allows for the expansion of the cellular PVC material to thedesired dimensions, as defined by the calibration chamber dimensions.

In one embodiment, the cellular PVC reinforced with at least onecontinuous fiber oriented in a first direction coated with an agent thatbonds the fibers to the cellular PVC of the present invention isextruded at a rate of about 0.1 feet per minute to about 50 feet perminute. In an alternate embodiment, the cellular PVC reinforced with atleast one continuous fiber oriented in a first direction coated with anagent that bonds the fibers to the cellular PVC of the present inventionis extruded at a rate of about 5 feet per minute to about 10 feet perminute.

In one embodiment, the cellular PVC reinforced with at least onecontinuous fiber oriented in a first direction coated with an agent thatbonds the fibers to the cellular PVC of the present invention passesfrom the calibration chamber to a cooling bath and is then cut to thedesired length.

In one embodiment, the cellular PVC material of the present inventionhas a specific gravity from about 0.3 to about 1.3.

The starting material may be treated with an agent to confer anadditional desired property, such as UV resistance, chemical resistance,and the like. Alternatively, the cellular PVC reinforced with at leastone continuous fiber oriented in a first direction coated with an agentthat bonds the fibers to the cellular PVC of the present invention maybe treated with an agent to confer an additional desired property, suchas UV resistance, chemical resistance, and the like.

Fiber Reinforcement Suitable for Use in the Present Invention

Fibers suitable as reinforcement in the present invention include, forexample, glass fibers, carbon fibers, aramid fibers, polyester fibers ornatural fibers, and the like. The selection of the particular fiber isreadily made by one of ordinary skill in the art, and may be influencedby factors, such as, for example, the particular exterior applicationthat the cellular PVC item is intended, the weight of the item, and thelike. The fiber provides the rigidity required to provide resistance totemperature-induced expansion and contraction of the cellular PVCmaterial. There can be one, or more than one fiber in the cellular PVCmaterial. The at least one continuous fiber used as reinforcement in thepresent invention are continuous, unbroken fibers that run the entirelength of the cellular PVC material.

In one embodiment, the at least one continuous fiber suitable asreinforcement in the present invention is a non-comingled glass fiber.The non-comingled glass fiber can be an electrical grade glass fiber, orE-glass fibers. Alternatively, the non-comingled glass fiber can beS-glass fibers. The choice of glass fiber is readily selected by one ofordinary skill in the art, and may be influenced by factors such as thedesired tensile strength, wet out properties, and the like.

In one embodiment, the at least one continuous fiber is a rovingconsisting of strands of non-comingled unidirectional glass fibers.

In an alternate embodiment, the at least one continuous fiber is a tapeconsisting of strands of non-comingled unidirectional glass fibers.

In one embodiment, the at least one continuous fiber suitable asreinforcement in the present invention is a co-mingled glass andthermoplastic fiber. The choice of co-mingled fiber is readily selectedby one of ordinary skill in the art, and may be influenced by factorssuch as the desired tensile strength, wet out properties, and the like.

In one embodiment, the at least one continuous fiber is a rovingconsisting of strands of co-mingled unidirectional fibers.

In an alternate embodiment, the at least one continuous fiber is a tapeconsisting of strands of co-mingled unidirectional fibers.

The directional orientation of the at least one continuous fiber, andthe spatial distribution of the at least one continuous fiber within, oron the cellular PVC material can readily be chosen by one of ordinaryskill in the art to provide resistance to temperature-induced expansionand contraction of the cellular PVC material.

For example, in one embodiment, the at least one continuous fiber isoriented in a first direction in the cellular PVC material. In oneembodiment, the first direction is longitudinal. In one embodiment, thefirst direction is aligned with the direction of extrusion of thecellular PVC material.

In one embodiment, the at least one continuous fiber is embedded as asingle layer within the cellular PVC material. In an alternateembodiment, the at least one continuous fiber is embedded as more thanone layer within the cellular PVC material. The direction of orientationof the more than one layers may all be the first direction.Alternatively, the direction of orientation of the more than one layersmay comprise the first layer having a first orientation, followed by thesubsequent layers having another orientation.

In one embodiment, the at least one continuous fiber is embedded withinthe cellular PVC material. In an alternate embodiment, the at least onecontinuous fiber is affixed to the outside of the cellular PVC material.

In one embodiment, the at least one continuous fiber is bonded to thecellular PVC material. In one embodiment, the bonding is achieved by abonding agent. In one embodiment, the bonding agent is applied as acoating on the at least one continuous fiber. The choice of bondingagent is readily selected by one of ordinary skill in the art, but mustform a bond between the at least one continuous fiber and the cellularPVC material sufficiently strong enough to provide resistance totemperature-induced expansion and contraction along the direction of theat least one fiber. In one embodiment, the bonding agent is polybutyleneterephthalate.

Exterior Systems

The fiber reinforced cellular PVC material of the present invention maybe used for any exterior system, such as, for example, siding, trimmoldings, door frames, window frames, decking and the like. In oneembodiment, the fiber reinforced cellular PVC material of the presentinvention is used to manufacture siding.

The fiber reinforced cellular PVC material of the present invention maybe used to form siding of any shape and dimension, limited only by thelimitations of the apparatus used in the manufacture process. Forexample, the fiber reinforced cellular PVC material of the presentinvention may be used to form siding consisting of a single strip.Alternatively, the fiber reinforced cellular PVC material of the presentinvention may be used to form siding comprising a profile resemblingmore than one strip. In the embodiments where the profile resembles morethan one strip, the profile may resemble two, or, alternatively, threeor more single strips of siding, for example.

The width of any single strip can be any suitable width, for example, 4inches wide, 6 inches, 7 inches wide, or any dimension that is suitablefor the situation where the siding is to be installed, and each profile,being one or more strips. One of skill in the art will readilyappreciate the need for building materials of various shapes, sizes andthicknesses and the desirability and potential for having such shapes,sizes and thicknesses manufactured as such or assembled or fastenedafter manufacture of alternate shapes, sizes and thicknesses.

For example, the fiber reinforced cellular PVC material of the presentinvention may be used to form siding of the shape disclosed in UnitedStates Patent Application US20100215907A1. Alternatively, the fiberreinforced cellular PVC material of the present invention may be used toform siding of the shape disclosed in United States Patent ApplicationUS20100058691A1. Alternatively, the fiber reinforced cellular PVCmaterial of the present invention may be used to form siding of theshape disclosed in U.S. Pat. No. 6,526,718 B2.

The present invention is further illustrated, but not limited by, thefollowing examples.

EXAMPLES Example 1 Evaluation of the Stability of Siding Material FormedFrom the Cellular PVC Material of the Present Invention to Temperature

Extruded siding was formed using the cellular PVC material of thepresent invention, wherein the at least one continuous fiber comprisedglass tape obtained from Cyclics Corporation. The extruded sidingcontaining the at least one continuous fiber comprising glass tape wasexposed to a temperature of −10° C. for one hour and the length of thematerial were recorded at three separate locations. The extruded sidingcontaining the at least one continuous fiber comprising glass tape wasallowed to return to room temperature (20° C.) and the length of thematerial were recorded at three separate locations. The extruded sidingcontaining the at least one continuous fiber comprising glass tape wasthen heated to 60° C. for one hour, and the length of the material wererecorded at three separate locations. The extruded siding containing theat least one continuous fiber comprising glass tape was then heated to65° C. for one hour, and the length of the material were recorded atthree separate locations. The extruded siding containing the at leastone continuous fiber comprising glass tape was allowed to return to roomtemperature (20° C.) and the length of the material were recorded atthree separate locations. Parallel measurements were taken in cellularPVC material lacking any fiber reinforcement. The results are shown inTable 1.

Room Temperature Freezer 60° C. Oven 65° C. Oven Final Sample LengthLength Length Length Length No 30 in 30 in 30 in 29 6/8 in 29 6/8 inreinforcement 76 cm 76 cm 76 cm 75.5 cm 75.4 cm 77 cm 77 cm 77 cm 76.5cm 76.4 cm Reinforcement 30 in 30 in 30 in 29 15/16 in 29 15/16 in 76 cm76 cm 76 cm 75.9 cm 75.9 cm 77 cm 77 cm 77 cm 76.9 cm 76.9 cm

The extruded siding containing the at least one continuous fibercomprising glass tape showed greater temperature stability at hightemperatures than the extruded siding without reinforcement.

Example 2 Flow Process by Which the Cellular PVC Material of the PresentInvention may be Formed

Step 1: Select the form profile, calibration chamber profile and buildthe die and extrusion apparatus that will form the cellular PVC materialof the desired profile and final specific gravity, with the at least onecontinuous fiber reinforcement located at the desired locations.

Step 2: Prepare the starting material, including determining the correctamount of PVC, resin, fillers and blowing agent.

Step 3: Determine the amount of fiber reinforcement required for theproduction run.

Step 4: Preheat the fiber reinforcement and the die and extrusionapparatus.

Step 5: Extrude the starting material through the die and combine thefiber reinforcement to the extrudate.

Step 6: Allow the cellular PVC material to expand, trapping the fiberreinforcement to the cellular PVC material by passing the extrudatecombined with the fiber reinforcement through the die into a calibrationchamber.

Step 7: Pull the expanded cellular PVC material through a cooling bathand cut the material to the desired length.

The above steps may be repeated, varying one, or more than one of theparameters can be altered to influence the final properties of thecellular PVC material.

Publications cited throughout this document are hereby incorporated byreference in their entirety. Although the various aspects of theinvention have been illustrated above by reference to examples andpreferred embodiments, it will be appreciated that the scope of theinvention is defined not by the foregoing description but by thefollowing claims properly construed under principles of patent law.

What is claimed is:
 1. A composition comprising cellular PVC reinforcedwith at least one continuous fiber oriented in a first direction withinthe cellular PVC material, wherein the at least one continuous fiber isbonded to the cellular PVC, and wherein the at least one continuousfiber provides resistance to temperature-induced expansion andcontraction along the direction of the at least one fiber.
 2. Thecellular PVC material of claim 1, wherein the at least one continuousfiber is coated with an agent that bonds the fibers to the cellular PVC.3. The cellular PVC material of claim 1, wherein the at least onecontinuous fiber is selected from the group consisting of co-mingledsilicate based fiber and thermoplastic fiber, non-comingled silicatebased fibers, non-comingled carbon based fibers and non-comingledpolyamide based fibers.
 4. The cellular PVC material of claim 3, whereinthe at least one continuous fiber is a silicate based fiber.
 5. Thecellular PVC material of claim 4, wherein the silicate based fiber is aglass fiber.
 6. The cellular PVC material of claim 3, wherein the atleast one continuous fiber is a co-mingled silicate based fiber andthermoplastic fiber.
 7. The cellular PVC material of claim 6, whereinthe silicate based fiber is a glass fiber.
 8. The cellular PVC materialof claim 2, wherein the agent that bonds the at least one continuousfiber to the cellular PVC is polybutylene terephthalate.
 9. The cellularPVC material of claim 1, wherein the first direction is aligned with thedirection at which the cellular PVC material is extruded.
 10. A methodto produce a composition comprising cellular PVC reinforced with atleast one continuous fiber oriented in a first direction within thecellular PVC material, wherein the at least one continuous fiber isbonded to the cellular PVC, and wherein the at least one continuousfiber provides resistance to temperature-induced expansion andcontraction along the direction of the at least one fiber comprising thesteps of: a. providing a starting mixture comprising PVC powder orpellets and a blowing agent; b. heating the starting mixture; c.extruding the starting mixture through a form; d. combining theextrudate with at least one continuous fiber coated with an agent thatbonds the fibers to the cellular PVC; e. passing the extrudate combinedwith the at least one continuous fiber in to a calibration chamber,allowing the combined extrudate to form cellular PVC reinforced with atleast one continuous fiber oriented in a first direction within thecellular PVC material, and allowing the cellular PVC reinforced with atleast one continuous fiber oriented in a first direction within thecellular PVC material to reach its final desired dimensions as definedby the calibration chamber dimensions; and f. cooling the cellular PVCreinforced with at least one continuous fiber oriented in a firstdirection within the cellular PVC material, and cutting the cellular PVCto the desired length.
 11. The method of claim 10, wherein the at leastone continuous fiber is coated with an agent that bonds the fibers tothe cellular PVC.
 12. The method of claim 10, wherein the at least onecontinuous fiber is selected from the group consisting of co-mingledsilicate based fiber and thermoplastic fiber, non-comingled silicatebased fibers, non-comingled carbon based fibers and non-comingledpolyamide based fibers.
 13. The method of claim 12, wherein the at leastone continuous fiber is a silicate based fiber.
 14. The method of claim13, wherein the silicate based fiber is a glass fiber.
 15. The cellularPVC material of claim 12, wherein the at least one continuous fiber is aco-mingled silicate based fiber and thermoplastic fiber.
 16. Thecellular PVC material of claim 15, wherein the silicate based fiber is aglass fiber.
 17. The method of claim 11, wherein the agent that bondsthe at least one continuous fiber to the cellular PVC is polybutyleneterephthalate.
 18. The method of claim 10, wherein the first directionis aligned with the direction of extrusion of the cellular PVC material.19. The method of claim 10, wherein the at least one continuous fibercoated with an agent that bonds the fibers to the cellular PVC is preheated prior to addition to the extrudate.